San Leandro, CA

Safeway - UHT | ESL Expansion


Shambaugh & Son, L.P.


Safeway, Inc.

Services Provided

  • Automation Engineering
  • Electrical
  • Fire Protection
  • Mechanical
  • Process Controls
  • Refrigeration 
UHT & ESL equipment installed at the Safeway San Leandro facility

Value Delivered

Shambaugh, in continuing partnership with Safeway Inc., was selected as the Design-Builder for the Extended Shelf Life (ESL) expansion of the San Leandro, CA milk processing and packaging plant. The project included 13,000-sqaure-foot of new construction and 60,000-square-foot of renovation of exiting process and warehouse space.

Client Objectives

This expansion gave Safeway Inc. in-house capability to produce ESL dairy and non-dairy products.

Scope of Services

The new/renovated facility includes, raw receiving and storage, separation and heat treatment, powder incorporation and liquid blending, UHT processing, ESL filling and packaging, CIP, dry storage and dock area, renovated cold storage area, a new electrical service and energy center to support the operation.

Equipment highlights include a direct steam injection UHT processor, ESL one-half gallon filler, two 250 BoHP boilers, two 275-ton air cooled chillers, a 350 ton evaporative cooler, and two 150 HP air compressors.


The expansion and renovation was completed while the plant was in full operation. Through careful coordination with the site operations group down time was limited to the main electrical switchover.